The six-day Timtos 2015 machine tool exhibition was the biggest yet; and with 1,015 exhibitors occupying 5,411 booths and 100,000m2 of exhibition space, this year’s event — the 25th — filled four halls, including the Yuanshan Expo Dome for the first time. Companies from 19 countries were exhibiting, and the show attracted some 53,000 visitors, of which around 7,130 were from overseas — an increase of 8.3% on the previous show in 2013.

Timtos was not only noteworthy for the number of exhibitors and visitors, but also for the amount of business it generated; deals concluded at the show, combined with follow-up business, are expected to top $2.1 billion. The prime driver for the show orders was the procurement meetings arranged by the show organisers — Taiwan External Trade Development Council (TAITRA) and Taiwan Association of Machinery Industry (TAMI).

These meetings, which generated some $35 million worth of business, were led by 29 major buyers from 18 countries (including China, India, Turkey and Russia); they were involved in 171 negotiations with 73 Taiwanese suppliers. These buyers included Doosan Infracore (Korea’s top CNC machine tool manufacturer), Kovosvit (a leading lathe manufacturer from the Czech Republic), Fagor (a Spanish control manufacturer), Finval (a Russian industrial group), Weber (a Ukrainian machine tool manufacturer), Hemaq (a Mexican machine tool importer), and Tezmaksan (a Turkish machine tool trader).

Chu Chih-Yaung, chairman of the Fair Friend Group, said: “On the first day of the show, we doubled our sales target to NT$200 million following an RMB120 million order for an automated cylinder head production line from a Chinese automotive manufacturer and a $4.5 million order from MMT Engineering — one of the largest machine tool agents in the USA.”

Fair Friend sales manager Andy Hung said the number of buyers placing orders ‘on the spot’ was greater than at any previous exhibition — plus there was a significant increase in the number of new customers.“Buyers came from more than 30 countries, including North and South America, India, Turkey, the Middle East, South Africa, North Africa, the UK, France, Germany and Russia.”

In order to enhance the exhibition’s international presence, the organisers incorporated an international association zone, which included seven machine and machine tool manufacturer associations: CMTBA from China, IMTMA from India, JMTBA from Japan, KOMMA from Korea, MIB from Turkey, UCIMU from Italy and VDW from Germany. Also present were Argentina’s machine tool importing association (CARMAHE), the Japan Society for Promotion of Machine Industry (JSPMI), and Turkey’s Machine Tools Industrialists and Businessman Association (TIAD).

Another feature of the show was the Taiwan Machine Tools Industry Award 2015 for Excellence in Research and Innovation, which attracted 51 entries from 48 companies. Winner of the Supreme Excellence Award for all CNC machine tools was Ching Hung Machinery & Electric Industrial for its SP3020L ultra-precision gantry-type wire EDM machine.

First prize in the Machining Centre category went to Tongtai Machine & Tool for its FV-236 gantry-type vertical machining centre. Soco Machinery won the Other NC Machine Tools category with its SLT-152 Fiber Laser (a five-axis tube-cutting machine), while Buffalo Machinery won the Component for Machine Tools category with its RAM-140L — a ram-type spindle for horizontal boring mills.

Increase in exports

According to TAMI chairman John Hsu, the total export value of Taiwanese machine tools in 2014 was $3.75 billion, an increase of 5.8% on 2013. The largest contribution to this total was made by machining centres, with an export value of some $1.28 billion, followed by lathes ($0.81 billion), presses and shearing machines ($0.50 billion).

China was the largest market, with a 32.4% share of exports at $1.2 billion, which equates to a growth of 7.3%. Next was the USA at £415 million (an increase of 3%), followed by Turkey at $208 million (a significant increase of 18.6%); and while Thailand was ranked fourth at $168 million, this represented a decrease of 25.3%. The other countries making up the top 10 export markets were Germany, the Netherlands, Russia, Indonesia, Malaysia and India.

“Originally, the Taiwanese machinery industry was expected to achieve a growth of 8% in 2014 and top the NT$1 trillion mark for output value. However, despite the growth in the US market, demand from China did not achieve expectations. Demand from Thailand also declined as a result of the country’s political turmoil.

"As a result, we narrowly missed our target, achieving an output of NT$985 billion. That said, we expect growth to continue in 2015. We also expect that the revenues of a number of our machine tool and machine parts manufacturers will exceed the NT$10 billion mark — companies such as Victor Taichung, Fair Friend Group, Tongtai Group, Goodway Machine Corporation and Hiwin Technologies Corporation.”

High-end products

Alan Lu, chairman of TAMI’s machine tool committee, said that the depreciation of the Japanese yen had significantly impacted Taiwanese manufacturers in 2014. “In the face of the yen depreciation, we can look at how Japanese machine tool manufacturers positioned themselves 20 years ago when the yen appreciated. Mass manufacturers like Mazak and Okuma set up factories in Europe, the USA and mainland China, while companies like Yasda focused on producing high-end products. Taiwan is like a small version of Japan; we should not focus on mass production but move toward producing specialised products.”

Highlighting the growth of the US market, he said that the upsurge of the manufacturing sector has played a part in stimulating the economy. “The investment in machinery is mainly being made by sectors that require advanced technology, such as energy, aerospace and automotive; this benefits German and Japanese manufacturers of high-end machinery used for precision processing. Taiwanese manufacturers have not yet had the chance to accumulate experience and be part of this supply chain; if Taiwanese machines do not offer specialised functions or manufacturing solutions, they will only be sold as general-purpose machines.”

Steve Lin, chairman of TAMI’s metal-forming machinery committee, says the FTAs (free-trade agreements) that China signed with South Korea, the USA, Japan and South Asian countries are further increasing Taiwan’s risk of being marginalised.

“In the face of the trend toward ‘smart automation’, Germany initiated Industry 4.0 in 2012 and the USA launched its ‘AMP project’ for a digital manufacturing sector; even mainland China gave clear instructions for the manufacturing sector in its ‘12th Five-Year Plan’ in 2011. With government support, it is hoped that Taiwanese metal-forming machinery manufacturers can accelerate their development of smart manufacturing and innovative services.

“Another hurdle being faced by Taiwanese manufacturers is the low-cost Chinese products entering Taiwan as a result of ECFA — the Economic Co-operation Framework Agreement. This is affecting mid- to low-end machinery makers in Taiwan, and a transition is a must, with Taiwanese manufacturers making products with higher levels of flexibility and customisation, as well as ‘smart automation’. The two trends in metal-forming equipment are all-electric technology and laser technology.

“The sluggish economy in mainland China in 2014 has had a tremendous impact on Taiwan; it also serves as a wake-up call that we must not have too much reliance on the mainland Chinese market. We must continue to develop our other export markets; South East Asia, in particular, has shown strong signs of recovery after the financial crisis, and its market is growing rapidly.”

At the cutting edge

Confirmation of Taiwanese manufacturers’ on-going development of higher levels of technology was the large number of five-axis machines at Timtos 2015. Under the Kafo brand from Kao Fong Machinery Co Ltd — represented in the UK by Rugby-based TDT Technology Ltd (www.tdt-technology.co.uk) — was the KFO-620-5AX.

This simultaneous five-axis machining centre features a travelling-column structure comprising substantial Meehanite castings, heavy-duty roller-type linear guideways, a rotary/tilt table (650mm in diameter) with a 300kg load capacity, and a 40-taper 12,000rev/min spindle (options include a 15,000rev/min 40-taper unit and a 20,000rev/min HSK 63 unit).

A spindle-oil chiller is fitted as standard. The work envelope is 620 x 520 x 460mm, and the rapid-traverse rate is 36m/min. The B axis has a tilt range of -40 to +110deg, and the C axis offers continuous rotation. A 24-station tool magazine is fitted as standard.

A wide range of options is available, including through-spindle coolant, a Heidenhain TT140 tool-measuring system, Heidenhain optical linear scales, and a Heidenhain infra-red probe system for automatic kinematic measurement and calibration of five-axis positioning.

Also from Kafo, but this time for the five-axis machining of large heavyweight workpieces, is the KG5A-3025. This gantry-type machine — one of a range offering X-axis travels to 6,000mm, Y-axis travels to 3,000mm and a Z-axis travel of 1,000mm — has a work envelope of 3,000 x 2,500 x 1,000mm, a 2,500 x 3,000mm table (max load 18,750kg) and a dual-axis milling head with speed options of 24,000rev/min (HSK A63), 15,000rev/min (HSK A100) and 12,000rev/min (HSK A100).

The A axis has a range of ±105deg, while the rotary C axis has a rotary range of ±200deg. Tool capacities range from 40 through to 120; control is via a Siemens 840DSL with a Heidenhain iTNC 530 available as an option.

Meanwhile, the NFP 500A-5AX from YCM (Yeong Chin Machinery Industries Co Ltd) is a high-speed high-precision five-axis double-column machining centre that is targeted at the aerospace, automotive mould-and-die industry. YCM is represented in the UK by Yeovil-based YMT (www.ymtltd.co.uk).

This particular machine has a 22.5kW 24,000rev/min HSK A63 spindle, a work envelope of 700 x 1,000 x 500mm, an A axis with a movement of +30 to -120deg, a 360deg C axis and a 500mm-diameter table with a maximum load capacity of 350kg. The linear axes offer a rapid-traverse rate of 50m/min and an acceleration of 0.7g. A 40-tool ATC is standard, and the maximum tool weight is 6kg.

YCM was also highlighting the benefits of its spindle technologies, which included its Isolated Direct Drive Spindle — IDD Plus, which allows continuous running at 16,000rev/min. IDD Plus minimises spindle growth by isolating the heat generated by the spindle motor from the spindle cartridge. Another feature of the spindle is its micro oil/air lubrication system, which directly injects a controlled amount of lubricant into each spindle bearing. YCM says its H-lub technology is 2.5-times more effective than a conventional lubrication system.

On the turning front, YCM highlighted its NT-2000SY, a twin-spindle turning centre with a maximum swing over the bed of 1,000mm diameter and a maximum swing over the carriage of 870mm diameter. The main spindle is rated at 15kW and has a maximum speed of 4,500rev/min, while the sub-spindle is rated at 7.5kW and 6,000rev/min.

Portal-type machine

Being demonstrated by Dah Lih Machinery Industry Co Ltd — represented in the UK by Sheffield-based Ward Hi-Tech Ltd (www.wardhitech.co.uk) — was its PT-128A-5X. This machine is based on the three-axis PT-128A, which features a double-column construction that offers the levels of stability required for high-speed machining. Moreover, the symmetrical design of the double-column structure is the optimum for suppressing distortion.

Finite element analysis was applied in the design of the overall structure, which features cross-shaped reinforcing ribs — and the X and Y axes are separately located on the base and columns to eliminate overlapped loads. Moreover, the table is fully supported to eliminate overhang and displacement problems — and the base features three-point location.

The three linear axes feature roller-type linear-motion guides, and there is the option of ballscrew cooling to prevent thermal deformation. On the PT-128A-5X, the 12,000rev/min BBT40 spindle is rated at 12.5/10kW, and the axes have travels of 600, 900 and 560mm for X, Y and Z respectively; the fourth/fifth-axis unit has an A axis of +30 to -120deg and 360deg of rotation for the C axis. The rapid-traverse rate for the linear axes is 30m/min, and control is via a Heidenhain CNC system.

New from Wele Mechatronic Co Ltd — a three-time past winner of the Taiwan Machine Tools Industry Awards and represented in the UK by Hinckley-based 2D CNC Machinery Ltd (www.2DCNC.co.uk) — was its UG800, a compact machine for the simultaneous five-axis machining of aerospace parts, as well as more-general applications.

This machine has an overhead moving gantry driven by twin ballscrews; moreover, the pivots for the trunnion are mounted in the side walls of the machine structure for optimum rigidity.

The A axis has a movement of +30 to -120deg and a maximum torque of 6,000Nm, while the C axis offers a full 360deg of movement and a torque of 2,000Nm. The work envelope is 800 x 950 x 650mm, and the 800mm-diameter table has a maximum load capacity of 1,000kg.

Combined milling and turning

Also from Wele — and designed for undertaking multiple machining procedures (including milling, turning, boring and drilling) — the MT-16W is a bridge-type machine with axis travels of 2,800, 3,060 and 800mm in X, Y and Z respectively. Moreover, it offers a 1,000mm W axis for the crossrail, a maximum turning diameter of 1,600mm, a maximum turning height of 1,700mm and a maximum swing diameter of 2,100mm.

The rotary table features Wele’s own hydrostatic bearing arrangement, which is designed to accommodate heavy loads and maintain long-term accuracy; automatic tool and head exchange is also provided (automatic tool exchange can be made with heads having either vertical or horizontal tool axes).

Wele was also displaying its VTC-1616-20 vertical turning and milling centre with three-axis control, a substantial bed, a double column and a B-axis rotating table that allows the machine to operate as a vertical turning lathe, a vertical machining centre or a horizontal machining centre; and with the ability to also undertake light grinding operations and use a variety of automatically exchanged angle heads, the VTC-1616-20 can finish-machine a wide range of components in one operation — including those requiring five-sided machining.

It has a 1,600mm-diameter table with a hydrostatic bearing arrangement, a maximum turning height of 1,200mm and a maximum swing diameter of 2,000mm. The travels are 810 to 1,180mm for the X axis, 1,050mm for the Z axis and 800mm for the W axis. The VTC series of machines offers table diameters up to 4m (this largest table is gear-driven and has a maximum torque of 139,766Nm).

Another vertical turning and milling centre with the ability to undertake ‘done in one’ machining was the VHL 1200ATC from You Ji, which is represented in the UK by Hove-based C Dugard Ltd (www.dugard.com).

As well as a crossrail-mounted vertical ram that accommodates driven tools (including those for grinding), turning tools and angled milling heads, this VTL also has a horizontal side-mounted ram that accommodates both live tools and turning tools, allowing complex parts to be completed without re-fixturing and increasing machining efficiency by more than 30%.

With regard to capacities, the VHL 1200ATC has a 1,250mm-diameter table driven by a 34kW motor (8,170Nm of torque), a maximum swing diameter of 1,600mm, a maximum turning diameter of 1,350mm and a maximum turning height of 1,200mm (this can be extended to as much as 1,800mm with increased column heights).

Both the vertical and horizontal spindles feature a 7.5/11kW drive for BT50 live tooling. An ATC with 10 tool positions is standard, although magazines with up to 60 tools can be specified as an option. A Fanuc control is fitted as standard; a Siemens 840D can be specified as an option.

Focus on versatility

Another take on five-axis (4+1) machining was offered by Victor Taichung Machinery Works Co Ltd, which has a UK subsidiary called Victor CNC (UK) Ltd (www.victorcnc
.com). The company’s Vcenter-AX800 is configured along the lines of a conventional vertical machining centre but features a swivel head (B axis) and rotary table to facilitate the machining of parts up to 1,000mm in diameter. The B-axis head incorporates a Hirth coupling with 1deg increments to optimise the 4+1 machining capability, while the C axis is clamped with a torque of 3,433Nm to accommodate heavy cutting.

Adjacent to the rotary table is a rectangular fixed table. Travels in X and Y are 1,600 and 700mm respectively, while travel for the Z axis is 600mm with the B axis in vertical mode and 1,000mm when it is horizontal; the total swivel capability is -30 to +110deg.

Rapids are 30m/min, and the BBT-40 spindle, which is rated at 15/18.5kW and 15,000rev/min, is served by a 40-tool ATC (optionally 60 tools).

Victor also introduced its Vturn-V1000, a relatively large VTL with a maximum turning diameter of 1,000mm and a table driven via a two-speed gearbox by a 37/45kW motor for heavy-duty cutting. This machine, which features Victor’s own BM-85 turret as standard, can be specified with the option of a C axis.

Hartford, which was celebrating its 50th anniversary at the show and is represented in the UK by TW Ward CNC Machinery Ltd (www.wardcnc.com), introduced its HMC-8 — a horizontal machining centre with a work envelope of 1,000 x 850 x 950mm, an 800 x 800mm pallet with a 1,500kg load capacity, an ISO 50 18.5/25kW 6,000rev/min geared spindle and a 40-tool ATC as standard.

The one-piece bed for the X and Z axes has been designed to maximise structural rigidity and ensure the highest possible machine accuracy, while a two-step X-axis configuration, combined with an extra-wide 893mm span, maximises the loading capability.

The pallet changer, which can accommodate a maximum workpiece height of 900mm (this ensures ample space for hydraulic and compressed-air supply units) is driven by a servo system that gives a tool change time of 10sec. The standard rapid-traverse rate is 30m/min (60m/min is available as an option).

Also new was Hartford’s 5A-650 — a gantry-type five-axis machining centre with a work envelope of 660 x 550 x 460mm, a 650mm-diameter table on the fourth/fifth-axis unit with a B-axis movement of +110 to -50deg and a full 360deg of rotation on the C axis. Rapids of 30m/min and a 24-tool ATC are standard.

The spindle is rated at 12.5kW, and there is a choice of spindle speeds ranging from 10,000 to 24,000rev/min. The machine also features what Hartford refers to as Intelligent NC. This includes: 2.5-D CAM with graphic conversational programming and the automatic generation of G codes; monitoring of the workpiece or tool via a CCD camera; daily and monthly statistics on utilisation rates; and a spindle speed and spindle load log.

New from Hardinge Bridgeport — represented in the UK by Southam-based Engineering Technology Group (www.engtechgroup.com) — was the Conquest V480 APC with automatic pallet changer for the 600 x 400mm pallets, which have a load capacity of 200kg each.

The work envelope is 480 x 400 x 430mm, and the No 40 12,000rev/min spindle is rated at 11kW (70Nm of torque) The maximum tapping speed is 3,000rev/min, the rapid-traverse rate is 36m/min, and the maximum cutting speed is 12m/min.

There is a swing-arm type tool-changer (bi-directional) that accommodates 20 tools and has a tool-change time of 2.2sec. Positioning accuracy is 0.005mm, and the repeatability is 0.003mm. Options include through-spindle coolant, fourth-axis table,spindle-oil chiller, tool and part probing, and Siemens 828D CNC system in place of the standard Fanuc unit.

Automated aluminium machining

A new livery across all its machine ranges was a notable feature of Tongtai Machine & Tool Co Ltd, which is represented in the UK by Matchmaker CNC, Leatherhead (www.matchmakercnc.co.uk). One of the notable new products being exhibited was the SH-4000 series of horizontal machining centres, which was developed specifically for the machining of smaller aluminium parts typically found in the automotive industries — such as brake calipers, ABS braking valves, differential covers and connecting arms.

Moreover, these machines have a width of just 1,750mm, allowing a number to be configured to form an automated production line; they can also be specified with an automatic pallet changer (SH-4000P).

The machine bed has a three-point support to ensure stable machine installation, while the column features a double wall and symmetrical design that optimises structural rigidity and minimises thermal distortion. Furthermore, a honeycomb-type structure for the column helps to reduce weight by 25% and increase rigidity by 20%, while the X-axis roller guides are on a stepped bed to increase structural rigidity and further minimise the weight of the moving column; and because the B-axis rotary table is driven by a roller gear cam with rolling contact between the rollers and the cam, it has a low starting torque. Moreover, it is suitable for high-speed rotation while maintaining high accuracy under long-term heavy-duty cutting.

Designed for high-speed cutting, the 15,000rev/min built-in spindle is rated at 18.5/25/37kW with corresponding torque ratings of 95/171/250Nm of torque. A ring-type magazine houses 40 tools (60 optional) and gives a tool-to-tool change time of 1.4sec (2.6sec chip to chip). Options include through-spindle coolant, linear scales, automatic tool-measuring and safety light curtain.

Moreover, these machines can be incorporated into a flexible manufacturing system with load/unload stations, stacker crane and manufacturing management system. There is also the option of Tongtai’s Intelligent Manufacturing System, which undertakes all aspects of production management, monitoring, tool management and workpiece management.

Heavy-duty teach lathe with Fagor control option

Recently released by L&L, and available in the UK under the brand name Tuscan from Axe & Status (www.axestatus.com), is a range of heavy-duty teach lathes. Available with cutting lengths of 1,035, 2,035, 3,035, 4,035 and 5,035mm, the swings over the bed for each model are 770mm (TA30) and 870mm (TA34); the swings over the cross-slide are 400 and 500mm respectively. The cast Meehanite bed, which has been designed to ensure the highest levels of rigidity and stability during cutting, features a ‘triple V’ and one flat slideway to optimise precision.

There are four spindle options: a 4in unit (A2-8) for higher-speed light machining; a 6in unit (A2-11) for general heavy-duty machining; a 9in unit (A2-15) for pipe work; and a 12in unit (A2-20) for even larger-diameter pipe work (this accommodates loads between centres of 7,000kg, and 8,500kg with two steady rests).

A hydraulic disk brake is available as an option. There is a choice of three controls: Fanuc OiTD (18.5/22kW spindle drive); Siemens 828D (22/33kW spindle drive); and Fagor 8055-TC (22/33kW spindle drive). All lathes feature two hand-wheels for two-axis simultaneous control. Standard equipment includes a 16in three-jaw chuck, a steady rest (30-300mm diameter), and an H4-250 hydraulic turret.

Options include an H4-VDI quick-change hydraulic turret, an eight-tool V8 hydraulic turret and a roller bracket for heavy large-diameter workpieces (this has a capacity for diameters of 300-500mm). Also available as an option is fully enclosed splash guarding, which has been designed to allow these machines to be loaded into a container without needing to remove the rear guard.

Also represented by Axe & Status, Pinnacle was demonstrating its BX700T. This five-axis machine with a B-axis head features continuous rotation of the C axis at 800rev/min (1,200rev/min as an option) for turning applications.